Wall construction system

ABSTRACT

A wall construction system including a first side member, a second side member and an interlocking member. The first side member has a first top connecting portion and a first bottom connecting portion. The second side member has a second top connecting portion and a second bottom connecting portion. The interlocking member is capable of removably attaching the first side member to the second side member so that the first side member is maintained in a spaced-apart relationship with the second side member.

REFERENCE TO RELATED APPLICATION

[0001] The application claims the benefit of U.S. Provisional Application No. 60/277,756, filed Mar. 21, 2001, the disclosure of which is hereby incorporated by reference.

FIELD OF THE INVENTION

[0002] The present invention relates generally to a wall construction system. More particularly, the present invention relates to a system of building blocks for constructing walls.

BACKGROUND OF THE INVENTION

[0003] For many centuries it has been known that buildings may be fabricated from a plurality of building components that each have a standardized size and shape. For example, bricks are used in conjunction with mortar to build various types of structures. Once the mortar cures, it retains the bricks in a stationary position with respect to each other and thereby maintains the building in a desired shape.

[0004] One significant drawback of using bricks is that it is difficult to separate the brick from each other if it is desired to modify the shape of the building. To overcome this limitation, blocks have been shaped with surfaces that permit adjacent blocks to interlock when it is desired to fabricate the building while enabling the blocks to be separated from each other when it is desired to change the shape of the building.

[0005] For example, Lofstrom, U.S. Pat. No. 2,902,853, discloses forming blocks with keyed surfaces on the upper and lower surfaces thereof for locking together adjacent rows of blocks. The blocks also include keyed end surfaces for locking together blocks in a row.

[0006] Nanayakkara, U.S. Pat. No. 6,105,330, discloses blocks for constructing a wall that include keyed side surfaces for interlocking adjacent blocks. The Nanayakkara blocks also include a reduced size portion extending from a lower surface thereof that seats in a top portion of a block placed underneath.

[0007] Cerrato, U.S. Pat. No. 5,899,040, discloses an interlocking wall system that is formed from interlocking blocks. The blocks have a generally rectangular configuration. A bottom of the block has a recess that is adapted to receive a complementary shaped region on a top of the block. A portion of the top also has a male dovetail region extending therefrom, which is adapted to engage a female dovetail region formed in a portion of the bottom.

[0008] Papke, U.S. Pat. No. 5,735,090, describes a system for constructing a foundation using modular blocks. Each of the blocks is oriented in a generally vertical orientation and has mating edge surfaces. The mating edge surfaces include a female connector and a male connector that seats in the female connector to interconnect adjacent blocks.

[0009] Zschoppe, U.S. Pat. No. 5,685,119, describes a wall construction system that includes a plurality of blocks. Each of the blocks includes at least one vertically oriented bore extending therethrough. When the blocks are stacked in an offset configuration, the bores on adjacent rows are aligned such that a retaining element may be extended therethrough to prevent the rows from moving with respect to each other.

[0010] Klym, U.S. Pat. No. 4,854,103, discloses a system with interlocking blocks. The blocks include a pair of side walls and a plurality of webs that extend between the side walls. The webs are offset vertically from the side walls such that the webs from a lower level block partially extend into an upper level block.

[0011] Pedersen et al., U.S. Pat. No. 4,688,362, discloses a modular building construction system that uses interlocking blocks. Each of the blocks includes a tongue and groove mechanism for retaining rows of blocks in a fixed configuration. The blocks also include a dovetail interlocking mechanism for engaging blocks in the same row.

SUMMARY OF THE INVENTION

[0012] The present invention relates to a wall construction system that permits the walls of a structure to be erected easily and quickly with only a 2 pound rubber mallet used to pound the cleats into the vertical slots of the horizontally placed plank courses.

[0013] The side members—the slotted planks—have top and bottom connecting beveled portions for holding together successive courses of the inside and outside walls which they form.

[0014] The interlocking members—the cleats—extend between and bind the side members to one another to create a finished wall with an inner and an outer surface. No additional fasteners, screws or nails of any sort need be used to accomplish this.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 is a perspective view of a wall constructed with the wall construction system of the present invention.

[0016]FIG. 2 is a perspective view of a first side of a side member of the wall construction system.

[0017]FIG. 3 is an end view of the side members.

[0018]FIG. 4 is a top view of the wall construction system.

[0019]FIG. 4a is a perspective view of an alternative system for connecting the side members for a toy construction application.

[0020]FIG. 4b is a perspective view of yet another alternative system for connecting the side members for a toy construction application

[0021]FIG. 5 is a perspective view of a side member with a slot to receive the cleat.

[0022]FIG. 6 is a perspective view of a cleat that binds the side members together.

[0023]FIG. 7 is a perspective view illustrating a cleat with a wiring or plumbing port.

[0024]FIG. 8 is a perspective view of a method of connecting butt ends of side members to extend the length of a wall.

[0025]FIG. 8a is an alternate method of connecting butt ends without additional fasteners.

[0026]FIG. 9 is a perspective view of a base plate of the wall construction system.

[0027]FIG. 10 is a top view of a corner interconnection mechanism for the wall construction system.

[0028]FIG. 11 is a top view of an alternative corner interconnection mechanism for the wall construction system with a cut out slot to pass electrical wiring, conduit and piping.

[0029]FIG. 12 is a perspective view of a corner post for the wall construction system showing the cut out slot for wiring and plumbing.

[0030]FIG. 13 is a top view of yet another corner interconnection mechanism for the wall construction system.

[0031]FIG. 14 is a top view of still another comer interconnection mechanism for the wall construction system.

[0032]FIG. 15 is a top view of a comer anchoring plate for use with the corner post in the wall construction system.

[0033]FIG. 16 is a top view of a door anchoring plate for use with the wall construction system.

[0034]FIG. 17 is a perspective view of an alternative embodiment of the wall construction system utilizing interlocking hollow blocks for even numbered courses of blocks.

[0035]FIG. 18 is a perspective view of a block for use with the wall construction system of FIG. 17 for odd numbered courses of blocks.

[0036]FIG. 19 is a perspective view of two interdigitating blocks for use with the wall construction system of FIG. 17.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] The present invention is directed to a wall construction system, as most clearly illustrated at 10 in FIG. 1. The wall construction system of the present invention includes standardized components that may be readily assembled into a variety of configurations to produce a building. A person of ordinary skill in the art will also appreciate that the concepts of the present invention may also be utilized on a smaller scale such that the wall construction system is suited for use as a toy as indicated by FIGS. 4a and 4 b.

[0038] An embodiment of the wall construction system, for buildings of variable dimensions, has two basic elements—long slotted planks and short cleats that fit into the vertically oriented slots in the plank to form a complete wall structure, with an outside wall, a dead air space, and an inside wall. Successive horizontal courses of the long planks lock into the courses above and below by means of beveled horizontally running surfaces, which bind the courses together when the cleats are inserted into the vertical slots in the planks.

[0039] The standardized components are particularly suited for use by persons who have little or no experience in erecting buildings because the standardized components interlock to produce structurally stable walls with the use of minimal tools or skill.

[0040] The standardized components used in conjunction with the wall construction system 10 invention generally include a side member 20 and an interlocking member 22. The interlocking members 22 extend between side members 20 to form a continuous hollow structure with an inside wall and an outside wall. They are alternately placed from course to course as shown in FIG. 1.

[0041] The side member 20 has a main body portion 24, a top connecting portion 26 and a bottom connecting portion 28, as most clearly illustrated in FIG. 2. The main body portion 24 has an outer surface 30 and an inner surface 32. The outer surface 30 and the inner surface 32 are each preferably substantially flat. However, the outer surface 30 may have different configurations depending on the intended use of the wall construction system 10. For example, if the wall construction system 10 is intended to be used in a dwelling that has the look of a log cabin, the outer surface 30 may have a convex shape so that the side member 20 looks similar to a conventional log.

[0042] The side members 20 preferably have a height of between 4 inches and 12 inches depending on the intended use for the wall construction system 10 and the materials from which the side members 20 are manufactured. The side members 20 preferably has a thickness of between 1 and 6 inches depending on the intended use for the wall construction system 10 and the materials from which the side members 20 are manufactured.

[0043] The side members 20 are preferably manufactured from wood. However, a person of ordinary skill in the art will appreciate that it is possible to use the concepts of the present invention with a variety of other materials such as plastic and steel.

[0044] The top connecting portion 26 and the bottom connecting portion 28 are designed with a complementary shape such that the top connecting portion 26 can engage the bottom connecting portion 28, as most clearly illustrated in FIGS. 2 and 3. Preferably, the top connecting portion 26 has a substantially flat surface 34 that is angled downward and inward. Similarly, the bottom connecting portion 28 has a substantially flat surface 36 that is angled downward and inward. Such a relationship between the top connecting portion 26 and the bottom connecting portion 28 is often referred to as a dovetail.

[0045] The top connecting portion 26 and the bottom connecting portion 28 are both oriented at an angle of between 30 degrees and 60 degrees and preferably about 45 degrees. The relationship between the surfaces 34 and 36 maximizes the contact area and thereby enhances the loads that may be placed on the wall construction system 10.

[0046] The interlocking member 22 preferably engages the side members 20 using a dovetail mechanism 40, as most clearly illustrated in FIG. 4. A person of ordinary skill in the art will appreciate that it is possible to use other configurations for engaging the interlocking member 22 and the side members 20 as in FIGS. 4a and 4 b.

[0047] Side edges of the interlocking member 22 preferably have a male portion 42 of the dovetail mechanism 40, as most clearly illustrated in FIGS. 3 and 4. The inner surface 32 preferably has a female portion 44 of the dovetail mechanism 40, as most clearly illustrated in FIGS. 4 and 5. The male portion 42 and the female portion 44 are preferably shaped in a substantially complementary manner such that the male portion 42 can seat in the female portion 44 to removably attach the interlocking member 22 to the side member 20.

[0048] The interlocking member 22 has a main body portion 50 that extends between the male portions 42, as illustrated in FIGS. 4 and 6. A thickness of the main body portion 50 is selected based upon the anticipated loads that will be placed upon the wall. For most applications, the main body portion 50 will have a thickness of less than about 6 inches and preferably between about 2 and 4 inches, with 3 ½ inches being preferable—the standard width of a 2×4 stud.

[0049] The interlocking member 22 is preferably manufactured from plastic. However, a person of ordinary skill in the art will appreciate that it is possible to use the concepts of the present invention with a variety of other materials such as wood, steel or composites.

[0050] To facilitate running pipes and/or wiring through the wall, the interlocking member 22 may include a bore 52 extending therethrough, as most clearly illustrated in FIG. 7. The bore 52 is preferably oriented in a substantially horizontal direction. Alternative placement of the 16 inch on center slots in the planks from course to course allows wiring to be placed in the dead air space without the need for ports in the cleats as shown in FIG. 1.

[0051] While it is possible to fabricate the interlocking member 22 with a length that is approximately the same as the height of the side members 20, the interlocking member 22 may have a height that spans multiple rows of the wall. Forming the interlocking member 22 in this manner further strengthens the wall because the interlocking member 22 transfers forces exerted upon a portion of the wall to a greater area and thereby minimizes the likelihood that the wall will be damaged.

[0052] The spacing between the interlocking members 22 is selected based upon the size of the wall being constructed and based upon the loads that are anticipated to be subjected upon the wall. For most applications, the interlocking members 22 are spaced at approximately 12 inches to 24 inches apart. The interlocking members 22 are preferably spaced at approximately 16 inches on center.

[0053] Ends of adjacent side members 20 are preferably attached together using a stud 56 that spans between the adjacent side members 20 and between the rows of side members 20, as most clearly illustrated in FIG. 8. For most applications the stud has a substantially square configuration with sides of approximately four to six inches long. The side members 20 are preferably attached to the stud 56 with screws 58. FIG. 8a illustrates an alternative method of joining the butt ends of the plank by alternating the placement of the inside and the outside wall abutments so they do not occur at the same site.

[0054] The wall construction system 10 also preferably includes a base plate 60 that is attached to a support surface 62 such as a concrete slab, as illustrated in FIG. 9. The base plate 60 has a substantially flat top surface 64 and a substantially flat bottom surface 66. Side surfaces 68 of the base plate 60 are oriented at an angle that is approximately the same as the angle at which the surface 36 of the bottom connecting portion 28 is oriented.

[0055] Side members 20 may be attached together at a corner with a corner post 70, as illustrated in FIG. 10. Screws 72 may be attached to the corner post 70 and the side members 20 from the inside to retain the components together while enhancing the outer appearance of the wall. The side members 20 have an angled side surface 74 where the side members intersect each other.

[0056] Alternatively, the side members 20 may be attached together by inserting screws 72 from the outside, as illustrated in FIG. 11. The side members 20 used in this configuration have substantially flat side surface 74. Such a configuration facilitates extending and attaching the side members 20 together with a screw 72. To facilitate running wires or tubing through the wall, the comer post 70 in this configuration has an angled inner surface 76, as illustrated in FIGS. 11, 12 and 13.

[0057] The angled inner surface 76 may span an entire length of the corner post 70 or only a portion of the length of the corner post 70. An alternative configuration of the corner mechanism is illustrated in FIG. 14.

[0058] To assist in maintaining the wall construction system 10 in a fixed location, a comer mounting plate 80 is mounted proximate to the intersection of walls, as most clearly illustrated in FIG. 15. The corner mounting plate 80 has a plurality of bolt holes 82 formed therein for anchoring the corner mounting plate 80 to the base 62. The comer mounting plate 80 also has an aperture 84 that is adapted to receive the comer post 70 and thereby prevent the comer post 70 from moving laterally. A second aperture can be placed at the junction of the inner walls for placement of a second comer post if desired

[0059] To provide additional reinforcement to the wall construction system 10 proximate to the location of doors, door mounting plates 90 are mounted to the base 62 proximate to the location of the door, as most clearly illustrated in FIG. 16. The door mounting plate 90 has a plurality of bolt holes 92 formed therein for anchoring the door mounting plate 90 to the base 62. The door mounting plate 90 also has an aperture 94 that is adapted to receive a door side post 96 to impart greater strength to the wall as desired.

[0060] In operation, the base plate 60 is attached to a support surface 62. Next, side members 20 are placed so that the bottom connecting portion 28 engages the sides of the base plate 60. The interlocking member 22 is then attached between the side members by sliding the interlocking member 22 vertically with respect to the side members 20 so that the male portions 42 on the interlocking member 22 engage the female portions 44 on the side members 20. This process is repeated to construct additional rows by repeating this process.

[0061] An alternative configuration of the wall construction system 110 is illustrated in FIGS. 17 and 18. In this embodiment, the wall is constructed from blocks 112 that a pair of side members 120 and a pair of interlocking members 122 that extend between the side members 120. A difference between the wall construction system 110 of this embodiment and the wall construction system 10 of the embodiment illustrated in FIGS. 1-16 is that the side members 120 and the interlocking members 122 are fixedly attached to each other in this embodiment and the blocks horizontally into place in contradistinction to the placement of the inside and outside planks of 10 and then locking them in place by the insertion of the cleat into the slots in the planks.

[0062] Each of the side members 120 has a top connecting portion 126 and a bottom connecting portion 128 for interconnecting adjacent rows. The interlocking members 122 are offset such that one of the interlocking members 122 is recessed between the side members 120 and one of the interlocking members 122 extends beyond the side members 120. Using this configuration permits adjacent blocks in a row to interlock.

[0063] It is contemplated that features disclosed in this application, as well as those described in the above applications incorporated by reference, can be mixed and matched to suit particular circumstances. Various other modifications and changes will be apparent to those of ordinary skill. 

1. A wall construction system comprising: a first side member having a first top connecting portion and a first bottom connecting portion; a second side member having a second top connecting portion and a second bottom connecting portion; and an interlocking member that is capable of removably attaching the first side member to the second side member so that the first side member is maintained in a spaced-apart relationship with the second side member.
 2. The wall construction system of claim 1, wherein the first top connecting portion is shaped substantially complementary to the first bottom connecting portion and wherein the second top connecting portion is shaped substantially complementary to the second bottom connecting portion.
 3. The wall construction system of claim 2, wherein the first top connecting portion is capable of engaging the first bottom connecting portion for attaching first side members in a stacked course relationship, and wherein the second top connecting portion is capable of engaging the second bottom connecting portion for attaching second side members in a stacked course relationship.
 4. The wall construction system of claim 1, wherein the first top connecting portion and the second top connecting portion each have a first angled surface that is angled downward and inward, and wherein the first bottom connecting portion and the second bottom connecting portion each have a second angled surface that is angled downward and inward.
 5. The wall construction system of claim 4, the first angled surfaces and the second angled surfaces are oriented at an angle of between 30 degrees and 60 degrees.
 6. The wall construction system of claim 1, wherein the interlocking member interlocks with the first side member and the second side member with a dovetail mechanism.
 7. The wall construction system of claim 6, wherein the dovetail mechanism includes a first female portion in the first side member, a second female portion in the second side member, and a male portion at the opposite edges of the interlocking members.
 8. The wall construction system of claim 1, wherein the interlocking member includes at least one aperture formed therein.
 9. The wall construction system of claim 1, wherein the interlocking member has a height that is approximately equal to integer multiples of a height of the first side member and the second side member.
 10. The wall construction system of claim 1, and further comprising a base that is attachable to a support surface, wherein the base has a base connecting mechanism that is capable of operably engaging the first bottom connecting portion and the second bottom connecting portion.
 11. A method of constructing walls, the method comprising: forming a first side member with a first top connecting portion and a first bottom connecting portion; forming a second side member with a second top connecting portion and a second bottom connecting portion; and removably attaching the first side member to the second side member with an interlocking member so that the first side member is maintained in a spaced-apart relationship with the second side member.
 12. The method of claim 11, and further comprising: attaching adjacent first side members by engaging the first top connecting portion with the first bottom connecting portion for attaching first side members in a stacked course relationship; and attaching adjacent second side members by engaging the second top connecting portion with the second bottom connecting portion for attaching second side members in a stacked course relationship.
 13. The method of claim 11, wherein the first top connecting portion and the second top connecting portion each have a first angled surface that is angled downward and inward, and wherein the first bottom connecting portion and the second bottom connecting portion each have a second angled surface that is angled downward and inward.
 14. The method of claim 11, and further comprising interlocking the interlocking member with the first side member and the second side member with a dovetail mechanism.
 15. The method of claim 14, wherein the dovetail mechanism includes a first female portion in the first side member, a second female portion in the second side member, and a male portion at opposite edges of the interlocking member.
 16. The method of claim 1 1, and further comprising forming the interlocking member with a height that is approximately equal to integer multiples of a height of the first side member and the second side member.
 17. The method of claim 11, and further comprising: providing a base that is attachable to a support surface, wherein the base has a base connecting mechanism; and operably engaging the first bottom connecting portion and the second bottom connecting portion with the base connecting mechanism.
 18. A method of constructing walls, the method comprising: fabricating a plurality of blocks comprising: forming a first side member with a first top connecting portion and a first bottom connecting portion; forming a second side member with a second top connecting portion and a second bottom connecting portion; and attaching the first side member to the second side member with an interlocking member so that the first side member is maintained in a spaced-apart relationship with the second side member; and operably attaching the plurality of blocks together by engaging the first top connecting portion and the second top connecting portion on a lower block with a first bottom connecting portion and a second bottom connecting portion on an upper block.
 19. The method of claim 18, and further comprising: providing a base that is attachable to a support surface, wherein the base has a base connecting mechanism; and operably engaging the first bottom connecting portion and the second bottom connecting portion on the lower block with the base connecting mechanism.
 20. The method of claim 18, wherein the first top connecting portion and the second top connecting portion each have a first angled surface that is angled downward and inward, and wherein the first bottom connecting portion and the second bottom connecting portion each have a second angled surface that is angled downward and inward. 